AD 2007-06-10 Airworthiness Directives; Rolls-Royce plc RB211-524 Series Turbofan Engines

This AD applies to the Rolls-Royce plc (RR) RB211-524 series turbofan engines listed in the following Table 1, with intermediate pressure compressor (IPC) stage 5 disk part numbers (P/Ns) listed in Table 2 of this AD, installed. Table 1.—Engine Models Affected           -524B-02 -524B-B-02 -524B3-02 -524B4-02 -524B4-D-02 -524B2-19 -524B2-B-19 -524C2-19 -524C2-B-19 -524D4-19 -524D4-B-19 -524D4X-19 -524D4X-B-19 -524D4-39 -524D4-B-39 -524G2-19 -524G2-T-19 -524G3-19 -524G3-T-19 -524H2-19 -524H2-T-19 -524H-36 -524H-T-36 These engines are installed on, but not limited to, Boeing 747, 767, and Lockheed L-1011 series airplanes. Table 2.—IPC Stage 5 Disk P/Ns Affected           LK60130 LK65932 LK69021 LK81269 LK83282 LK83283 UL12290 UL15743 UL15744 UL15745 UL19132 UL20785 UL20832 UL23291 UL25011 UL36821 UL36977 UL36978 UL36979 UL36980 UL36981 UL36982 UL36983 UL37078 UL37079 UL37080 UL37081 UL37082 UL37083 UL37084

You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done. Exempted Disks (f) For engines with an IPC stage 5 disk P/N listed in Table 2 of this AD, reworked to RR SB No. RB.211-72-E182, Revision 1, dated July 30, 2004, no further action is necessary. Cycle Limits (g) Comply with the reduced cyclic life limits in Table 3 of this AD within 30 days after the effective date of this AD, or conduct optional qualifying nondestructive test (NDT) inspections before December 1, 2008 to extend the IPC stage 5 disk life, as specified in paragraph (i) of this AD. Table 3.—Cyclic Life Limits Without Qualifying NDT Inspection Date of reduced life limit Engine models -524G2, G2-T, G3, G3-T, H2, H2-T, H-36, H-T-36 -524D4, D4-B, D4-B-39, D4X, D4X-B, D4-39 -524B2, B2-B, C2, C2-B -524B-02, B-B-02, B3-02, B4-02, B4-D-02 November 30, 2002 13,500 cycles-in-service (CIS) 16,150 CIS 16,000 CIS 16,200 CIS. April 1, 2003 13,500 CIS 13,500 CIS 13,500 CIS 14,000 CIS. December 1, 2003 12,000 CIS 13,500 CIS 13,500 CIS 14,000 CIS. December 1, 2004 11,000 CIS 13,500 CIS 12,000 CIS 12,000 CIS. December 1, 2005 11,000 CIS 12,000 CIS 12,000 CIS 12,000 CIS. (h) On December 1, 2008, the revised cyclic life limits specified in Table 4 of this AD become effective. Incorporate the revised cyclic life limits specified in Table 4 of this AD into the RR Time Limits Manual, 05-10-01. Table 4.—Cyclic Life Limits on December 1, 2008 Date of reduced life limit Engine models -524G2, G2-T, G3, G3-T, H2, H2-T, H-36, H-T-36 -524D4, D4-B, D4-B-39, D4X, D4X-B, D4-39 -524B2, B2-B, C2, C2-B -524B-02, B-B-02, B3-02, B4-02, B4-D-02 December 1, 2008 7,830 CIS 8,700 CIS 8,900 CIS 9,000 CIS. Optional Inspections (i) Before December 1, 2008, you may perform an optional NDT inspection on-wing or at each shop visit to extend the disk life. Guidance for these inspections is provided in paragraphs (j) or (k) of this AD. Optional Inspections at Shop Visit (j) Perform optional inspections at shop visit, as follows: (1) Remove corrosion protection from IPC stage 5 disk. Information on corrosion protection removal can be found in the Engine Maintenance Manual. (2) Perform a visual inspection and a binocular inspection of the IPC stage 5 disk for corrosion pitting at the cooling air holes and defender holes in the disk front spacer arm. Follow paragraph 3.C. of the Accomplishment Instructions of RR ASB No. RB.211-72-AD428, Revision 5, dated March 18, 2005. The RR Engine Maintenance Manual, Inspection Check-00 (ATA 72-32-31-200-000), contains limits for corrosion pitting of the IPC stage 5 disk. (3) If the disk has corrosion pitting in excess of limits, remove the disk from service. (4) If the disk is free from corrosion pitting, perform a magnetic penetrant inspection (MPI) of the entire disk as follows: (i) For RB211-524G2-T, RB211-524G3-T, and RB211-524H-T series engines, the RR Engine Maintenance Manual, Inspection Check 08 (ATA 72-32-31-200-008), contains limits for corrosion pitting of the IPC stage 5 disk. (ii) For RB211-524G2, RB211-524G3, and RB211-524H series engines, the RR Engine Maintenance Manual, Inspection Check 09 (ATA 72-32-31-200-009), contains limits for corrosion pitting of the IPC stage 5 disk. (iii) If the disk passes the MPI and you find no cracks, complete all other inspections, re-apply corrosion protection to the disk, and return the disk to service using the cyclic limits allowed by paragraph (m) of this AD. RR Repair FRS5900 contains information on re-applying corrosion protection. (5) If the disk has corrosion pitting that is within limits, do the following: (i) Perform an ECI on all disk cooling air holes, defender holes, and inner and outer faces. Use paragraph 3.D. of the Accomplishment Instructions of RR ASB No. RB.211-72-AD428, Revision 5, dated March 18, 2005. The RR Engine Maintenance Manual, Inspection Check-00 (ATA 72-32-31-200-000), contains limits for corrosion pitting of the IPC stage 5 disk. (ii) If the disk passes the ECI and you find no cracks, perform an MPI on the entire disk. (iii) If the disk passes the MPI and you find no cracks, re-apply corrosion protection to the disk, and return the disk to service using the cyclic limits allowed by paragraph (m) of this AD. Optional On-Wing Eddy Current Inspections (k) You may perform an optional on-wing ECI of the IPC stage 5 disk only once between shop visit inspections as follows: (1) For RB211-524B2/C2, RB211-524B/B3, and RB211-524B4/D4 series engines, use paragraphs 3.A. through 3.F. of the Accomplishment Instructions of RR SB No. RB.211-72-E148, dated March 13, 2003, and RR SB No. RB.211-72-E150, Revision 1, dated June 4, 2003. (2) For RB211-524G2, RB211-524G2-T, RB211-524G3, RB211-524G3-T, RB211-524H, RB211-524H-T, RB211-524H2, and RB211-524H2-T series engines, use paragraphs 3.A. through 3.M. of the Accomplishment Instructions of RR SB No. RB.211-72-E171, Revision 1, dated February 8, 2005. (3) If the disk passes the ECI and you find no cracks, you may extend the cycle life as specified in paragraph (m) of this AD. Definition of Shop Visit (l) The manufacturer defines a shop visit as the separation of an engine major case flange. This definition excludes shop visits when only field maintenance type activities are performed in lieu of performing them on-wing (such as to perform an on-wing inspection of a tail engine installation on a Lockheed L-1011 series airplane). Cyclic Life Extension (m) Disks that pass an optional inspection may remain in service after that inspection for the additional cycles listed in the following Table 5, until the next inspection, until the cyclic life limit published in the RR Time Limits Manual, 05-10-01, is reached, or December 1, 2008, whichever occurs first. Table 5.—Cyclic Life Extension Type of extension Engine models -524G2, G2-T, G3, G3-T, H2, H2-T, H-36, H-T-36 (cycles) -524D4, D4-B, D4-B-39, D4X, D4X-B, D4-39 (cycles) -524B2, B2-B, C2, C2-B (cycles) -524B-02, B-B-02, B3-02, B4-02, B4-D-02 (cycles) Extension After Passing MPI 1,600 2,000 2,000 2,000 Extension After Passing In-Shop ECI 3,800 4,500 4,500 4,500 Extension After Passing On-Wing ECI 1,000 1,200 1,200 1,200 Disks That Have Been Intermixed Between Engine Models (n) The RR Time Limits Manual, 05-00-01, contains information on intermixing disks between engine models. Alternative Methods of

This AD results from the manufacturer issuing a revised Alert Service Bulletin (ASB) to remove certain disks from applicability and to allow an on-wing eddy current inspection (ECI) on RB211-524G and RB211-524H series engines. The actions specified in this AD are intended to prevent failure of the IPC stage 5 disk, which could result in uncontained engine failure and possible damage to the airplane.